JP3107821B2 - Restartable mechanical fastening system and method of manufacturing the same - Google Patents

Abstract

The invention is a refastenable mechanical fastening system, made of free formed prongs joined to a substrate. The prongs taper and are nonperpendicularly oriented relative to the plane of the substrate. The prongs also have an azimuthal angle relative to the machine direction of the substrate. Each prong has an engaging means projecting laterally from the periphery of the prong. The free formed prongs are manufactured by the process of depositing liquid material onto a moving substrate, stretching the liquid material in a direction parallel to the plane of the substrate, severing the stretched material to form the distal end and engaging means of the prong, and imparting an azimuthal angle to the prong. The advantageous usage of the fastening system in an article of manufacture, such as a disposable absorbant garment, specifically a diaper.

Description

Description: FIELD OF THE INVENTION The present invention relates to mechanical fastener systems that can be re-locked, and more particularly, to fastening systems having free-form prongs and methods of making such fastening systems.

Background of the Invention Mechanical fastener systems that can be stopped again are well known in the art. Typically, such fastening systems have a prong and a receiving surface that is joined to two main components, the substrate, and engages a complementary second component. The protruding prongs of the fastening system penetrate the receiving surface and engage or catch strands or fibers on the receiving surface. The resulting mechanical damping and physical obstruction prevents the fastening system from coming off the receiving surface until the separating force exceeds the peel or shear strength of the fastening system.

Currently, refastenable mechanical fastening systems are made in at least two general ways. One method requires a plurality of filaments, each of which is formed into two prongs. An example of a fastening system formed in this way can be found in September 1955.
U.S. Patent No. 2,717,43 granted to Domesteral on March 13
No. 7, and U.S. Pat. No. 3,943,981 issued to Debrabander on March 16, 1976, teaching a raised pile of loops. Related teachings 1980
U.S. Patent No. 4,216, issued to Shams et al.
No. 257, and U.S. Pat. No. 4,454,183, issued to Wallman on Jun. 12, 1984, and U.S. Pat. No. 4,463,486, issued to Mazda on Aug. 7, 1984. These references teach heating the ends of the polymer monofilament. Another related teaching of the fastening system formed by the first method is disclosed in U.S. Pat.
No. 4,307,493 and U.S. Pat. No. 4,330,907 issued to Ochiai on May 25, 1982.

A second general method commonly used in the manufacture of mechanical fastening systems is described in U.S. Pat.
A method of forming or extruding a fastening system as exemplified in U.S. Patent No. 3,594,863, issued to Arb on March 27. Continuous injection molding was performed on July 27, 1971.
Taught in U.S. Pat. No. 3,594,865, issued to Arb, dated.

Various prong structures are illustrated in the prior art. For example, the above-cited references teach a fastening system having a stem of substantially constant cross section. U.S. Pat. No. 3,708,833, issued to Livich et al. On January 9, 1973, includes:
A prong protruding vertically from the substrate, somewhat tapered from a proximal end to a distal end, is disclosed.

European Patent Application No. 0,276,970, filed on January 26, 1988 by Procter & Gamble in the name of Scripps, describes a stem with a constant cross-section oriented at an angle of about 30 ° to about 90 ° with respect to the base. A fastening device having the same is disclosed.

The prior art does not show a manufacturing method for forming free-form prongs. Further, the prior art does not show the structure of a mechanical fastening system in which the prongs are oriented in a direction other than perpendicular to the substrate and the prongs have tapered sides. Furthermore, the prior art does not show a manufacturing method for forming free-form prongs oriented substantially transverse to the machine direction of the substrate.

It is an object of the present invention to provide a free-form mechanical fastening system formed by a manufacturing method similar to gravure printing. It is another object of the present invention to provide a fastening system having a prong with a taper protruding in a direction other than perpendicular from the associated substrate.
It is yet another object of the present invention to provide a fastening system having free-form prongs oriented substantially transverse to the machine direction of the substrate.

SUMMARY OF THE INVENTION The present invention has a fastening system for mounting to a complementary receiving surface. The fastening system includes a substrate and at least one free-form prong comprising a base, a shank, and an engagement means. The base of the prong is bonded to the substrate, and the shank is adjacent to and protrudes outward from the base. The engagement means is joined to the shank and projects laterally beyond the periphery of the shank. The shank is oriented in a direction other than perpendicular to the plane of the substrate. The shank has a leading edge and a trailing edge, which constitute a leading edge angle and a trailing edge angle, respectively. The leading edge angle and the trailing edge angle are substantially different from each other, so that the sides of the shank are not parallel. The shank also has an azimuth. This azimuth is from about 1 ° to about 180 ° with respect to the machine direction, preferably from about 20 ° to about 160 °.

The fastening system may be made according to a method comprising heating the heat-sensitive material sufficiently to reduce its viscosity for processing, and preferably to at least one of its melting points. Means are provided for depositing individually discrete amounts of the heated material. The substrate to which the material is to be bonded is transferred to a means for applying the material in a first direction. The materials are deposited on the transferred substrate in individually separated quantities. The individually separated amounts of the material are then stretched in a direction having a vector component substantially parallel to the plane of the substrate. The stretched material is cut to form the distal end and the engagement means, and the shank is angled from about 1 ° to about 180 °, preferably from about 20 ° to about 160 °.

An exemplary suitable non-limiting use of a fastening system formed in accordance with the method of the present invention is associated with disposable substrate garments such as diapers. This example of one use of the invention is described in detail below.

BRIEF DESCRIPTION OF THE DRAWINGS Although this specification ends with the claims which particularly point out and distinctly claim the invention, the invention is not limited to the same elements being numbered the same, and Will be better understood by reading the following description with reference to the associated drawings, shown by adding one or two primes or increasing the number by 100.

FIG. 1 is a perspective view of the fastening system of the present invention with the engagement means oriented in substantially the same direction; FIG. 2 is a side view of one prong of the fastening system shown in FIG. FIG. 3 is a side view of a second embodiment having substantially hemispherically shaped engagement means, and FIG. 4 is a schematic side view of one device that can be used to form the fastening system of the present invention. FIG. 5 is a perspective view of the fastening system of the present invention with the engagement means oriented in a substantially random direction; FIG. 6 shows the topsheet and core in partial cross-section;
FIG. 7 is a perspective view of a disposable substrate garment using the fastening system of the present invention; FIG. 7 is a plan view of one prong having an azimuth of about 90 °; FIG. FIG. 9 is a front view showing only a portion of one device that can be used to form a fastening system of the present invention with a prong, and FIG. 9 forms a fastening system of the present invention with a prong having an azimuthal angle. FIG. 6 is a plan view of a second device that can be used for the following.

Embodiment The fastening system 20 of the present invention comprises at least one prong 22 and, preferably, a substrate as shown in FIG.
24 has an array of prongs 22 joined in a predetermined pattern. The prong 22 has a base 26, a shank 28, and an engagement means 30. The base 26 of the prong 22 is in contact with and adheres to the substrate 24 and supports the proximal end of the shank 28. The shank 28 protrudes outward from the base material 24 and the base 26. The shank 28 terminates at a distal end joined to the engagement means 30. The engagement means 30 project radially laterally from the shank 28 in one or more directions, and are similar to hook-shaped branches. As used herein, the term "lateral" means having a vector component substantially parallel to the plane of the substrate 24 at the primary prong 22 to be considered. The engagement means 30 can be secured to a complementary receiving surface (not shown) by projecting laterally from the periphery of the shank 28. The engagement means 30 is joined to the distal end of the prong 22 and is preferably adjacent thereto. Engagement means
Obviously, 30 may be joined to the prong 22 at a location between the base 26 and the distal end of the shank 28.

The array of prongs 22 may be formed in any suitable manner, including the method of forming free-form prongs 22 described and claimed below. As used herein, the term "free-form" means a structure that is not removed from a mold cavity or drawing die in solid form, ie, with a defined shape. The prongs 22 are deposited on a separate substrate 24 in a molten, preferably liquid, state and cooled to a desired structure and shape, as described below, and preferably solidified.

The free-form array of prongs 22 is preferably formed by a method similar to that commonly known as gravure printing. Using this method, as shown in FIG. 4, a substrate 24 having two sides is passed between two nips 70 of two generally cylindrical rolls, a print roll 72 and a receiving roll 74. Rolls 72 and 74 have substantially parallel centerlines and are maintained in contact with substrate 24 as it passes through nip 70. One roll, called the printing roll 72, has an array of closed-ended blind cavities, called cells 76, corresponding to the desired pattern of prongs 22 to be deposited on the substrate 24. The second roll, called the receiving roll 74,
As it passes through the nip 70, it exerts a reaction on the print roll 72 that positions the substrate 24 against the print roll 72. The liquid heat-sensitive material, preferably a thermoplastic material, from which the prongs 22 are to be formed is supplied from a heated source such as trough 80. This thermal material is introduced into the cell 76 as the print roll 72 rotates about its center line. The cell 76 containing the heat-sensitive material conveys the heat-sensitive material until contact with the substrate 24 is made, and the material is deposited on the substrate 24 in a desired pattern.

As the relative movement between the substrate 24 and the rolls 72 and 74 continues, the prongs 22 are stretched in a transverse component substantially parallel to the plane of the substrate 24 to form the shank 28 and the engagement means 30.
Finally, the moir of the prong 22 is cut from the engaging means 30 by the cutting means 78. The prongs 22 contract due to the viscoelasticity of the thermoplastic material. Prong 22 retracts under the action of gravity,
It is believed that shrinkage occurs during cooling. Prong 22
Is then cooled and preferably solidified into a solid structure with a shank 28 and engaging means 30 adjacent.

Fastening system 20 is secured to a complementary receiving surface. As used herein, the term "receiving surface" to which the engaging means 30 of the fastening system 20 is secured is defined by one or more strands complementary to the engaging means 30. Alternatively, with respect to any plane or surface having an exposed surface with closely aligned openings constituted by fibers, in an alternative embodiment, the exposed surface is such that the engagement means 30 is captured and there is no interference Can be locally elastically deformed so that it cannot be pulled out. The opening or local elastic deformation allows the engagement means 30 to be in the plane of the receiving surface, with the receiving surface strand (or the deformed area) interposed between the openings (or the deformed areas). The area that has not undergone deformation) is fixed to the fastening system until the user desires or exceeds either the peel strength or the shear strength of the fastening system 20.
Ensure that 20 is not pulled out or released. The plane of the receiving surface may be flat or curved.

The receiving surface with the strands or fibers is such that the openings between the strands or fibers are sized such that at least one engaging means 30 can penetrate into the plane of the receiving surface, and that the strands are "Complementary" when sized to engage or catch
It can be said that. A locally deformable receiving surface is said to be "complementary" if at least one engagement means 30 can cause a local disturbance in the plane of the receiving surface. This disturbance resists removal or separation of the fastening system 20 from the receiving surface.

Suitable receiving surfaces include reticulated foam, knitted wovens, non-woven materials, and stitch bonded loop materials, such as the VERICLO brand loop material sold by Velcro USA, Inc. of Manchester, NH. A particularly suitable receiving surface is Stitch Bonded Fabric No. 970026 sold by Milliken Company of Spartanburg, South Carolina.

Referring again to FIG. 2, the components of the fastening system 20 will be discussed in more detail.
The substrate 24 of the fastening system 20
It must be strong enough to prevent tearing or separation between the 22 and the prongs 22 must be a surface that adheres easily and can be joined to the article to be fixed as the user desires. There must be. As used herein, the term "joint" refers to a state in which a first member or first component is directly or indirectly attached or connected to a second member or second component. With regard to
In the indirectly attached or connected state, the first member or first component is attached or connected to the intermediate member or intermediate component and the intermediate member or intermediate component is connected to the second member or second component. Attached or connected. The association between the first member or first component and the second member or second component is intended to be maintained over the life of the article. "Substrate" is the exposed surface to which one or more prongs 22 are bonded.

The substrate 24 must be rollable and flexible so that it can be bent or flexed into the desired configuration to maintain conventional manufacturing methods, and must be liquid The prongs 22 must be able to withstand the heat of the liquid prongs 22 without being melted or adversely affected until solidified. Further, the substrate 24 must be available in various widths. Suitable substrates include knitted fabrics,
Woven, non-woven, rubber, vinyl, film, certain polyolefin films, and preferably kraft paper are included. The basis weight of the kraft paper 1 m ² per 0.08 kg (3000 per square foot £ 50) has been found to be suitable.

The base 26 is a generally flat portion of the prong 22 and is attached to the substrate 24 and is adjacent the proximal end of the shank 28 of the prong. As used herein, the term "base" refers to a substrate that is in direct contact with
The portion of the prong 22 that supports the shank 28. It is not necessary to reveal the boundary between base 26 and shank 28. It is only important that the shank 28 does not separate from the base 26 during use, and that the base 26 does not separate from the substrate 24. The cross-section of the base 26 provides sufficient structural integrity and, therefore, an area based on the density of the pattern of prongs 22 and the length of the shank of the individual prongs 22 for the desired peel and shear strength of the fastening system 20. It must be provided, and furthermore, it must provide adequate adhesion to the substrate 24. If a long shank 28 is used, the base 26 should generally have a large cross-sectional area to provide sufficient adhesion to the substrate 24 and proper structural integrity.

The shape of the leg print of the base 26 on the substrate 24 is not critical and can be expanded in any direction to provide greater structural integrity and thus greater peel strength in the expanded direction. As used herein, the term “leg print” relates to the flat contact area of the base 26 on the substrate 24. The aspect ratio of the leg print size should not be too large, otherwise the prongs 22 will not be stable if force is applied parallel to the shorter side of the leg print. Aspect ratios of about 1.5: 1 or less are preferred, and substantially circular leg prints are more preferred.

For the embodiment described herein, a base 26 having a diameter of about 0.030 "to 0.050" with a substantially circular footprint is suitable. If a fastening system 20 having a large peel strength and high shear strength in a specific direction is to be manufactured, the cross-sectional area of the base 26 is increased so that the strength and structural integrity with respect to an axis orthogonal to the specific direction are increased. It is good to change so that it may enlarge in such a direction. With this change, the prongs 22 become stronger when pulled in the direction in which the base 26 expands.

The shank 28 is adjacent to the base 26 and protrudes outward from the base 26 and the substrate 24. As used herein, the term "shank" refers to the portion of the prong 22 intermediate and adjacent the base 26 and the engagement means 30. The shank 28 constitutes the lengthwise spacing of the engagement means 30 from the substrate 24. As used herein, the term "longitudinal"
Unless specified as a direction having a vector component toward the plane of the substrate 24 at the base 26 of 22, it refers to a direction having a vector component away from the substrate 24, which direction is at the base 26 of the prong 22. The vertical distance to the plane of the substrate 24 is increased.

A starting point 36 is associated with the shank 28 and base 26 of each prong 22. The “start point” of the shank 28 is a point that can be considered as the center of the base 26, and
Located in 26 leg prints. The starting point 36 is found by looking at the prong 22 from a side view. A "side view" is any direction radially toward the shank 28 and the base 26, which direction is further parallel to the plane of the substrate 24. If the fastening system 20 is manufactured in the manner described and claimed below, the prongs 22 are oriented in the machine direction relative to the movement of the substrate 24 through the nip 70 and transversely to the machine when determining the starting point 36. It is preferable to look at. However, this is not necessary.

The lateral distance between the distal edges of the leg prints of the base 26 for the particular side view to be considered is determined and this distance is bisected to reveal the midpoint of the base 26 for such a view. When the leg print of the base 26 is bisected for the particular side view to be considered, minor discontinuities (such as streaks and irregularities that are likely to occur when attached to the substrate 24) are ignored.
This point is the starting point of the shank 28.

The shank 28 makes an angle α with the plane of the substrate 24. As used herein, the term "substrate plane" refers to the substrate at the base 26 of the primary prong 22 considered.
For 24 flat surfaces. The angle α is determined as follows. View the prongs 22 in the outline drawing. The “outline drawing” of the prong 22 is one of two specific side views and is determined as follows. The prongs 22 are visually inspected from a side view so that the direction with the largest lateral protrusion 38 becomes apparent. "Lateral protrusion" refers to the base
From the center of 26, the starting point 36 of the shank 28, to the projection of the farthest point laterally on the prongs 22 visible in such a view, such points are lowered towards the plane of the substrate 24. When projected in the length direction, that is, in the vertical direction.
Is a distance taken in a direction parallel to the plane.

It will be apparent to those skilled in the art that the maximum lateral protrusion 38 is the protrusion from the starting point 36 to the outer periphery of the shank 28 or engagement means 30. Prongs 22 to maximize lateral protrusion 38
Is a profile view of such a prong. Further, if the fastening system 20 is manufactured in the manner described and claimed below, and the maximum lateral protrusion 38 is fully oriented in the machine direction, the outline drawing is viewed transverse to the machine direction. It will also be apparent to those skilled in the art that It will also be apparent that if the maximum lateral protrusion 38 is oriented generally transverse to the machine direction, the outline view is in machine direction.
The side view shown in FIG. 2 is one of the external views of the prong 22. It will be apparent to those skilled in the art that there is another outline view, approximately 180 ° opposite the illustrated outline view, with the maximum lateral protrusion 38 facing the left of the viewer. Either of these two outline drawings is almost equally suitable for the means and uses described below.

The starting point 36 of the shank 28 is determined from the outline drawing as described above for the prong 22. Then, while maintaining the prongs 22 in the outline drawing, the virtual cutting plane 40-substantially parallel to the plane of the base material 24 at the point or segment of the prong 22 having the largest vertical distance from the plane of the base material 24.
Make sure that 40 touches the periphery of the prong 22. This corresponds to the highest part of the prong 22. The virtual cutting plane 40-40 is then raised to a height such that the virtual cutting plane 40-40 intersects the prongs 22 at the longitudinal height of 3/4 of the vertical distance from the plane of the substrate 24. Substrate from the highest point
Approach 24 to one-fourth of such largest vertical distance.

Next, three points on the prongs 22 are determined using the virtual cutting planes 40-40. The first point is that the cutting plane is prong
It is the point that intersects with the leading edge 42 of 22 and this point is 75% leading edge 44
Call. The “leading edge” is the top of the perimeter of the shank 28 that moves longitudinally away from the plane of the substrate 24. The second point is located approximately 180 ° through the center of the prong 22 and this point
The point where the cutting plane 40-40 intersects the trailing edge 46 of the prong 22 and is referred to as the 75% trailing edge point 48. "Trailing edge" refers to substrate 24
A longitudinally extending top of the shank 28, generally opposite the leading edge 42. Of course, the straight line connecting these two points lies in the cutting plane 40-40, which is bisected to obtain the intermediate point 47 of the virtual cutting plane 40-40. Then, the shank at the midpoint 47 of the virtual cutting plane 40-40 and the base 26
Draw a straight line connecting the starting point 36 of 28. The angle α between this line and the plane of the substrate 24 is the angle α of the shank 28.

In other words, the angle α formed by the shank 28 with respect to the plane of the substrate 24 is the midpoint 47 of the cutting plane determined in any side view.
The line connecting the starting point 36 and the starting point 36 is a 90 ° complement of the angle formed by the perpendicular. Accordingly, the shank 28, and particularly the radial direction of the starting point 36, is substantially parallel to the plane of the substrate 24 and, when viewed in any direction orthogonal to the perpendicular, of the substrate 24, The smallest angle with respect to the plane is the angle α of the shank 28. When viewing the prong 22 with the maximum lateral protrusion 38 oriented in the machine direction substantially in the machine direction or at about 180 ° from the machine direction, or the maximum lateral protrusion 38 is oriented transverse to the machine direction. When the prongs 22 are viewed substantially transverse to the machine direction, the angle α of the shank 28 is clearly about 90 °. However, as discussed above,
The angle α to be measured is far off the perpendicular,
Accordingly, the profile of the prongs 22 is typically reduced from substantially transverse to the machine direction for the prongs 22 oriented in the machine direction, and substantially for the prongs 22 oriented transverse to the machine direction. The angle α is determined when viewed from the machine direction.

The angle α of the shank 28 may be substantially perpendicular to the plane of the substrate 24, or preferably at an acute angle to the plane of the substrate 24 to increase the peel strength in a particular direction. Oriented in relationship. This particular direction is substantially parallel to the maximum longitudinal protrusion 38. However, the angle α of the shank 28 must not be too far from the vertical. If too far apart, a fastening system 20 with a directionally specified shear strength is obtained. For the embodiment described herein, a shank 28 having an angle α of about 45 ° to about 80 °, preferably about 65 °, is superior. Shank 28
Is less than about 80 °, the shank 28
It is considered not oriented perpendicular to the 24 planes (transverse orientation is irrelevant).

The imaginary cutting plane 40-40 and outline drawing can also be used to determine the angle of the leading edge 42 and the trailing edge 46 with respect to the plane of the substrate 24. To determine these angles, the 75% leading edge points 44 and 75
The% trailing edge 48 is determined as described above. Base 26
The base leading edge 50 at is found as follows. A line passing through the base 26 as seen in the outline drawing crosses the leading edge 42 of the shank 28. This intersection is the “base leading edge”. As described above, minor discontinuities in the shank 28 near the base 26 that is attached to the substrate 24 are not taken into account when determining the base leading edge 50. A 75% leading edge point 44 and a base leading edge point 50 are connected by a straight line. This straight line forms an angle βL with the plane of the substrate 24, which angle is open towards the starting point 36, ie the center of the shank 28. Angle βL is referred to as the angle of leading edge 42, or simply the leading edge angle.

The base trailing edge point 52 is located 180 ° from the base leading edge point 50 through the center of the base 26, and is obtained as follows. A line passing through the leg print of the base 26 as seen in the outline drawing crosses the trailing edge 46 of the shank 28. This intersection is the “base trailing edge”. As described above, minor discontinuities in the shank 28 near the base 26 that is attached to the substrate 24 are not taken into account when determining the base trailing edge 52.
As described above, the 75% trailing edge point 48 and the base trailing edge point 52 are connected by a straight line. This straight line forms an angle βT with the plane of the substrate 24, which angle is open toward the starting point 36, ie the center of the shank 28. Angle βT is referred to as the angle of trailing edge 46, or simply the trailing edge angle. The leading edge 42 and trailing edge 46, angles βL and βT, constitute the parallel sides of the shank 28. If the angles .beta.L and .beta.T of the leading edge 42 and the trailing edge 46 are not complementary to each other (and do not add up to approximately 180.degree. Arithmetic), the sides of the shank 28 are not parallel. If the sides of the shank 28 are not parallel, the straight line forming the angle βL (connecting the base leading edge point 50 and the 75% leading edge point 44) and the straight line forming the angle βT (connected to the base trailing edge point 52)
75% trailing edge 48) intersect either above or below the plane of substrate 24. Angle βL of leading edge 42 and trailing edge 46
And βT are not equal, and if the lines making up these angles intersect above the plane of the substrate 24 (outward in the longitudinal direction of the base 26), the prongs 22 will It tapers towards the engagement means 30. Only when the angles βL and βT of the leading edge 42 and the trailing edge 46 have the same direction, that is, are oriented in the same direction, the magnitude of the supplementary angle is determined to be the same. And the angles βL and βT of the trailing edge 46 and the sides of the shank 28 are parallel.

A shank 28 having a leading edge 42 forming a leading edge angle βL at an angle of about 45 ° ± 30 ° with the substrate is suitable. Substrate and about
Trailing edge 46 forming trailing edge accuracy βT at an angle of 65 ° ± 30 °
Is appropriate. The angles βL and βT of the leading edge 42 and trailing edge 46 are within this range, and are advantageously relative to the substrate 24 to provide high shear and peel strength without excessive need for prong material. In order to obtain a tapered shank 28 oriented vertically, the shank 28 having the angle α of the shank 28 within the above-mentioned range is excellent.

The above measurements are based on the goniometer 100-0 sold by Laem-Hart, Inc. of Mountain Lake, NJ.
This is easily done using the 0115 type. If more precise measurement is desired, outline drawing, starting point 36, cutting plane
40-40, leading edge angle βL, trailing edge angle βT, base points 50 and 5
It will be appreciated by those skilled in the art that the determination of the 2,75% points 44 and 48 and the angle α of the shank 28 can be advantageously made by taking pictures of the prongs 22. The Scanning Electron Microscope Model 1700 sold by Amley of New Bedford, Mass. Has been found to be particularly good for this purpose. If necessary, a number of pictures may be taken to determine the maximum lateral protrusion 38 and, therefore, which outline drawing to use.

The shank 28 must protrude longitudinally from the base 26 a distance sufficient to separate the height of the engagement means 30 from the substrate 24. The engagement means 30 thereby easily catches, ie, easily engages, the strands on the receiving surface. The relatively long shank 28 has the advantage that it can penetrate deeper into the receiving surface, so that the engagement means 30 can capture or engage a greater number of strands or fibers. Conversely, the relatively short shank 28 has the advantage of obtaining a relatively strong prong 22, but such a shank has a correspondingly small penetration into the receiving surface and therefore a Or, it is not suitable for receiving surfaces such as wool or loosely stitch bonded material with low fiber density.

If a receiving surface of knit or woven material is used, the longitudinal length from the substrate 24 to the highest point or segment is about 0.5 mm (0.020 inch), preferably at least about 0.7 mm ( A relatively short shank 28 of 0.028 inches is suitable. If the caliper uses a receiving surface of high loft material of about 0.9 mm (0.035) or greater, at least about 1.2 mm (0.047 inches), preferably at least about 1.2 mm (0.047 inches)
A relatively long shank 28 with a 2.0 mm (0.079 inch) longitudinal dimension is more suitable. As the length of the shank 28 increases and the shear strength decreases accordingly, the density of the prongs 20 of the fastening system 20 may be increased to compensate for such a decrease in shear strength.

As described above, the longitudinal length of the shank 28 determines the longitudinal spacing of the engagement means 30 from the substrate 24. The “lengthwise interval” is the shortest vertical distance from the plane of the base material 24 to the periphery of the engagement means 30. For the engaging means 30 having a constant outer shape, the longer the length of the shank 28 in the longitudinal direction, the longer the distance between the engaging means 30 and the base material 24 in the longitudinal direction. When the engagement means 30 of the fastening system 20 is longitudinally spaced at least about twice the diameter of a strand or fiber of a given receiving surface, and preferably about 10 times the diameter of such a strand or fiber, Such strands or fibers are well captured, engaged and retained. For the examples described herein, about 0.2 m
Prongs 22 having a longitudinal spacing of from 0.008 inches to 0.03 inches (m to about 0.8 mm) are superior.

The cross-sectional shape of the shank 28 is not important. Thus, the shank 28 may have any desired cross-section according to the parameters described above for the cross-section of the base 26. "Cross section"
A flat area of any part of the prong 22 taken perpendicular to the shank 28 or engagement means 30. As mentioned above, the shank 28 is provided at the distal end of the shank and at the engagement means 30 of the prong 22.
It is preferably tapered so that its cross-section decreases as it approaches the length and the lateral direction. This configuration,
The moment of inertia of the shank 28 and the engagement means 30 is correspondingly reduced, so that when a separating force is applied to the fastening system 20, a substantially constant stress is applied to the prongs 22 and thereby incorporated into the prongs 22. Reduce the amount of extra material that is added.

To maintain the desired profile over a wide range of prong 22 sizes, a substantially constant cross-sectional area ratio can be used to measure the prongs 22. One ratio that controls the overall taper of the prong 22 is the ratio of the cross-sectional area of the base 26 at the highest height of the prong 22 to the cross-sectional area of the prong 22. The term "highest height" refers to the point or segment of the shank 28 or engagement means 30 that has the greatest vertical distance from the plane of the substrate 24. Typically, the ratio of the cross-sectional area of the base 26 to the highest height cross-sectional area is from about 4: 1 to about
9: 1 prongs 22 are better.

As described above, the base 26 tapers from a diameter of the base 26 of about 0.030 inches to about 0.050 inches to a highest height diameter of about 0.41 mm to about 0.51 mm (0.016 inches to 0.020 inches). A substantially circular shank 28 has been found to be superior for the embodiments discussed herein. Specifically, the diameter at the highest height is about 0.46mm (0.
An approximately circular cross-section of about 018 inches has a cross-sectional area at the highest height of about 0.17 mm ² (0.0003 square inches). about
A generally circular cross-section of the base 26 of 1.0 mm (0.040 inch) results in a cross-sectional area of the base 26 of approximately 0.81 mm ² (0.0013 square inches). In this configuration, the ratio of the cross-sectional area of the base 26 to the cross-sectional area at the highest height is about 5: 1. This ratio is in the range described above.

The engagement means 30 is joined to the shank 28 and is preferably adjacent to the distal end of the shank 28. The engagement means 30 is
Projecting outwardly away from the periphery of the shank 28 and projecting in the longitudinal direction, i.e. towards or towards the substrate 24
It has a vector component that moves away from 24. As used herein, the term "engaging means" refers to any protrusion transverse to shank 28 (shank
This protrusion resists separation or removal from the receiving surface (rather than minor indentations around 28). The term "perimeter" means the outer surface of the prongs 22. The term "radial" refers to a direction from or toward the normal to the substrate 24 through a starting point 36 approximately at the center of the footprint of the base 26.

In particular, the lateral protrusion has a vector component that is parallel to and toward the plane of the substrate 24. It will be appreciated that it has both a lateral vector component and a longitudinal vector component of the engagement means 30 and the shank 28. It is not important that the distal end of the shank 28 be pointed or that the boundary between the shank 28 and the engagement means 30 be unclear. As the engaging means 30 has a surface having a vector component parallel to and facing the plane of the base material 24,
It is only necessary that the longitudinally oriented surface of the shank 28 be interrupted.

Either of the lateral projections of the engaging means 30 and the shank 28 may be greater as desired. As shown in the attached drawing,
The engagement means 30 is preferably arcuate as a whole,
It is desirable to have a curved curve. If the engaging means 30 has an inwardly curved curve, the engaging means 30
It has a longitudinally approaching segment at a location laterally spaced from 24 or base 26. This segment need not be radially directed toward the starting point 36, but is laterally directed toward the shank 28.

Engaging means 30 of each prong 22 of fastening system 20
Should extend laterally in approximately the same direction if a relatively small peel strength is desired, or provide a nearly isotropic peel strength in any lateral direction It should be randomly oriented so that
The engagement means 30 may be a hook-shaped branch that protrudes greatly from one side of the shank 28, has a generally convex outer shape, and penetrates an opening in the receiving surface to form a strand or strand on the receiving surface. The fiber is captured at the inner radius of curvature 54 of the engagement means 30. Interference between the engagement means 30 and the strands or fibers of the receiving surface prevents the fastening system 20 from leaving the receiving surface until the peel or shear strength of the fastening system 20 is increased. The lateral protrusion of the engagement means 30 must not be too large. If too large, the engagement means 30 cannot penetrate the opening in the receiving surface. The cross-section of the engagement means 30 must be large enough to penetrate the opening in the receiving surface.

The engagement means 30 comprises structural integrity that provides sufficient shear and bending strength to match the desired peel and shear strength of the fastening system 20 with an array of prongs 22 of a given density. As long as the engagement means 30
The cross-sectional area and outer shape of are not important. For the embodiment described herein, the maximum lateral protrusion 38 from the center of the base 26 to the distant lateral periphery is in the form of a hook in the range of about 0.79 mm to 0.90 mm (0.03 inch to 0.04 inch). Means30
Is suitable.

The array of prongs 22 may be of any desired pattern and density to provide the required peel and shear strength for the particular application of the fastening system 20. In general, as the density of the array increases,
The shear strength increases in direct proportion thereto. Individual prongs
22 interferes with the engaging means 30 of the adjacent prong 22,
Such engagement means must not be closely aligned so as not to prevent capturing the strands or fibers on the receiving surface. If the prongs 22 are very closely aligned, compression or tangling of the strands or fibers on the receiving surface will occur, blocking the openings between the strands or fibers. Conversely, the prongs 22 may be excessively spaced and require an excessive area of the substrate 24 to provide a fastening system 20 of adequate shear and peel strength. Not be.

The prongs 22 are preferably arranged in rows so that each prong 22 is equally spaced from adjacent prongs 22. These rows may be oriented in the machine direction and transverse to the machine direction according to the manufacturing methods described and claimed below. Overall, each of the rows of prongs 22 in the machine direction and the rows transverse to the machine direction are substantially even across the fastening system 20 and the receiving surface when a separating force is applied to the fastening system 20 and the receiving surface. To provide a strong stress field,
It must be equally spaced from the machine direction row of adjacent prongs 22 and the row transverse to the machine direction.

As used herein, the term "pitch" is measured in either the machine direction or transverse to the machine direction between the centers of the leg prints of the bases 26 of the prongs 22 in adjacent rows. Related to distance. Typically, the pitch in both directions is about 1.02 mm to about 5.08 mm (0.04 inch to 0.4 mm).
A fastening system 20 having an array of prongs 22 of 20 inches is suitable, and a pitch of about 0.08 inches is preferred. Adjacent rows transverse to the machine direction are preferably substantially transverse to the machine direction to double the distance in the machine direction between adjacent rows transverse to the machine direction. It is shifted by half a pitch.

The prongs 22 may have from about 2 to about 20 rows per cm (5 to 50 rows per inch) in both the machine direction and transverse to the machine direction, preferably about 9 to 9 rows per cm in each direction. It can be thought of as being arranged in a matrix on a 1 cm 2 grid with an array of prongs 22 arranged in rows (23 rows per inch). The grid provides a fastening system 20 having from about 4 to about 400 prongs 22 (25 to 2500 per square inch) for a 1 cm 2 substrate 24.

The prongs 22 of the fastening system 20 are stable and retain their shape when solidified,
It may be made of any heat-sensitive material that is not brittle enough to break when subjected to a separating force. As used herein, the term "thermal" refers to a material that gradually changes from a solid state to a liquid state upon heating. It is believed that breakage occurs when the prongs 22 break or when the separating force is applied and the reaction cannot be maintained when the separating force is applied. Preferably this material is
Approximately 24.600000 kg / m ² measured according to ASTM Standard D-638
~ 31.6 million kg / m ² (3500 pounds per square inch to 4
It has an elastic tensile modulus of 5000 pounds).

In addition, the material of the prongs has a melting point low enough to facilitate processing so that the shank 28 can be stretched and the engaging means 30 can be easily formed according to the manufacturing method described below, and the melting point of the material. It must have a relatively high viscosity to provide tack and high consistency at near temperatures. It is also important that the prongs 22 have to be viscoelastic so that the parameters affecting the structure of the prongs 22, in particular the shape of the engagement means 30, can be varied greatly. Materials having a complex viscosity of about 20 to about 100 Pascal seconds at the temperature of application to the substrate 24 are suitable.

Viscosity may be measured on a Rheometrics 800 mechanical spectrometer using a dynamic mode of operation with a sampling frequency of 10 Hertz and a strain of 10% material. Disc and plate shaped profiles are preferred, specifically having a radius of about 12.5 mm and a spacing between disc and plate of about 1.0 m.
This is done using m disks.

Plate 22 is preferably made of a thermoplastic material. The term "thermoplastic" refers to a non-crosslinked polymer of a thermosensitive material that flows under heat or pressure. Hot melt adhesive thermoplastics are particularly good at manufacturing the fastening system 20 of the present invention, particularly in accordance with the methods described and claimed below. As used herein, the term "hot melt adhesive" relates to a thermoplastic molding material that is usually solid at room temperature, becomes fluid at high temperatures, and is applied in a molten state. An example of a hot melt adhesive can be found in Irving Skailt, Second Edition, "Adhesive Handbook", published in 1977 by Van Nostrand Reinhold, Inc., 135 West 50th Street, New York, NY, 10020. By referring to this document, the contents disclosed in this document are incorporated herein. Polyester and polyamide hot melt adhesives are particularly suitable and preferred. As used herein, the terms "polyester" and "polyamide" refer to a repeating chain of ester and amide groups, respectively.

When a polyester hot melt adhesive was selected, an adhesive having a complex viscosity of about 23 ± 2 pascal seconds at about 194 ° C. was found to be superior. If a polyamide hot melt adhesive is selected, about 90 ± 10 at about 204 ° C
It was found that an adhesive having a complex viscosity of Pascal second was excellent. Polyester hot melt adhesives sold by Bostic, Inc. of Middleton, Mass., As number 7199, have been found to be excellent. Polyamide hot melt adhesives sold under the trademark Macromelt 6300 by Henkel, Inc. of Kankerquay, Ill. Have been found to be excellent.

In the second embodiment of the fastening system 20 'shown in FIG. 3, the engagement means 30' is entirely hemispherical (mushroom).
Shape. The term “hemisphere” refers to a generally rounded shape, protruding in many directions, including but not limited to hemispheres and spheres. The structure of the engaging means 30 'having this shape, particularly a generally spherical shape, typically has an advantage that disturbance of the receiving surface when the engaging means 30' is removed from the receiving surface is reduced. Having. This allows the receiving surface to be reused many times by reducing visible damage to the receiving surface. If a hemispherically shaped engagement means 30 'is selected, the shank 28' will preferably be substantially orthogonal to the plane of the substrate 24 ', simplifying entry of the receiving surface into the opening, Less damage to the receiving surface when the engagement means 30 'is disengaged from the receiving surface. Shanks 28 'having an angle α' of about 70 ° to about 90 ° are suitable.

Engagement means 3 with proper balance and hemispherical shape overall
0 'to form the prong 22', the engagement means 30 '
Must protrude radially from the periphery of the shank 28 'by a lateral distance sufficient to capture the strands on the receiving surface, but the shank 28' has not been able to securely support the mass of the engagement means 30 '. Shank 28 'is not protruding enough to be unstable for other reasons. shank
As the angle α 'of 28' decreases, i.e., moves away from the vertical, the mass and cross-sectional area of the engagement means 30 'to the structural integrity of the shank 28' becomes more important.

A tapered shank with a ratio of cross-sectional area to diameter of the base 26 'up to the highest height and a diameter of about 80 ° and an angle α' of the shank 28 'of about 80 ° is superior. It will be appreciated that the highest height measurement is taken from the highest height of the shank 29 'and not from the engagement means 30.

In an embodiment where there is no smooth transition from the shank 28 'to the engagement means 30 and the boundary between the shank 28' and the engagement means 30 'is easily determined, as shown in FIG.
The imaginary cutting plane 40'-40 'is separated from the plane of the substrate 24' by the substrate 2
It is 3/4 of the vertical distance to the plane tangent to the point of the engagement means 30 'closest in length to the plane 4'. Then, using the cutting plane 40'-40 ', the angle α' of the shank 28 ',
The leading edge angle βL ′ and the trailing edge angle βT ′ are determined as described above.

The engagement means 30 'is provided in each transverse direction at the distal end of the shank 28'.
It must project radially from the periphery of 29 'at least about 25% of the diameter of the distal end 29' of the shank 28 ', and preferably at least about 38% of such diameter. In other words, if the diameter of the distal end 29 'of the shank 28' is standardized to 1.0, the diameter of the engagement means 30 'must be at least 1.5, preferably the distal end 29' of the shank 28 '
Is at least 1.75 times the diameter of Furthermore, the base
The diameter of 26 'is approximately 2.about the diameter of the distal end 29' of the shank 28 '.
Must be 0x. The height of the shank 28 'is about 1.5 to about 1.5 times the diameter of the distal end 29' of the shank 28 'so as to be properly longitudinally spaced from the substrate 24' of the engagement means 30 '.
Must be 2.0 times. The longitudinal dimension of the engagement means 30 'may be in the range of about 0.5 to about 1.5 times the diameter of the distal end 29' of the shank 28 '.

The fastening system 20 'of FIG. 3 is made by heating the engagement means 30 and the distal end of the fastening system 20 of FIG. 2 to at least the melting point. This ensures that the base 26 'and the proximal end of the shank 28' are not heated to at least the melting point and the engagement means 30 and the prongs 22
By approaching a distal end of the heat source directed longitudinally toward the plane of the substrate. A suitable method is to increase the highest height of the prongs from about 3.3 mm to about 10.1 mm of a heat source such as a hot wire heated to about 440 ° C.
(0.1 inch to 0.4 inch).

The leading edge angle βL ′ and the trailing edge angle βT ′ of the prong 22 ′
Is the same as the leading edge angle and the trailing edge angle of the engaging means of the corresponding hook-shaped branch-shaped prongs 22 on which the prongs 22 'having hemispherical shaped engaging means are formed. This is accomplished by heating, melting and flowing the engaging means 30 of FIG.
This is because the angle α ′, the leading edge angle βL ′, and the trailing edge angle βT ′ of the shank 28 ′ do not substantially change when the angle is 30 ′.

For the aforementioned Milliken 970026 receiving surface, the engagement means 30 'of FIG.
mm (0.001) lateral and longitudinal dimensions, the base 26 'has a diameter of about 0.30 mm to about 0.045 mm (0.012 inches to 0.002 inches) and the distal end 29' has a diameter of 0.016 mm to about 0.016 mm.
0.020mm (0.0006 inch to 0.0007 inch) shank 2
8 'must be placed above. The distal end 29 'of the shank 28' is about 0.44 mm to about 0.4 mm above the plane of the substrate 24 '.
Must be located at 50mm (0.017 "to 0.020") and engaging means 30 'should be between about 0.56mm to about 0.70mm.
mm (0.022 inch to 0.028 inch), preferably about 0.64
Must have a lateral projection 38 'of 0.025 inches.

Manufacturing Method The fastening system 20 according to the present invention may be manufactured using a modified gravure printing method. Gravure printing is well known in the art, as shown in U.S. Patent No. 4,643,130, issued February 27, 1988 to Sheath et al. By reference to the patent to illustrate the general state of the art, the disclosure of that patent is hereby incorporated by reference. Referring to FIG. 4, the substrate 24 is provided with a printing roll 72.
And a nip 70 formed between the two rolls of the receiving roll
Pass through. Rolls 72 and 74 have center lines that are substantially parallel to each other and are positioned substantially parallel to the plane of substrate 24. Rolls 72 and 74 are rotated about their respective centerlines, and the surface velocity at nip point 70 is approximately equal in both magnitude and direction. If desired, both the print roll 72 and the receiving roll 74 are driven by an external motive force (not shown), or one of the rolls is driven by an external motive force and the second roll is frictionally engaged with the first roll. It is better to drive according to circumstances. An AC motor with an output of about 1500 W provides a suitable driving force. By rotating, the rolls 72 and 74 actuate the application means for applying the prongs 22 to the substrate 24.

The attachment means adapts to the temperature of the liquid material of the prongs 22,
It must be possible to provide a substantially uniform pitch between the prongs 22 in both the machine direction and transverse to the machine direction to obtain the desired density of prongs 22 in the array. Further, the attachment means must be capable of forming prongs with varying diameters of the base 26 and height of the shank 23. In particular, the printing roll 72 constitutes an application means for applying the prongs 22 on the substrate 24 in the desired array (or other pattern) described above in accordance with the manufacturing method of the present invention. The term "adhesion means" refers to the conversion of liquid prong material from bulk to substrate
24 relates to any means for transferring in an amount corresponding to the individual prongs 22. The term "adhering" means transferring prong materials from a bulk form and separating such materials onto a substrate 24 in units corresponding to individual prongs 22.

One suitable means of depositing the prong material on the substrate 24 is an array of one or more cells 76 on a print roll 72. As used herein, the term "cell" refers to the transfer of prong material from a material source to a cavity 24, which is transferred to the cavity 24.
Print roll 72 deposited in the form of a separate unit on 24
The cross-sectional area of the cell 76 on the surface of the print roll 72 with respect to the cavity or other components
It almost matches the shape of the leg print of the base 26 of the 22. cell
The cross section of 76 must be approximately equal to the desired cross section of base 26. The depth of the cell 76 is one of the factors that determine the length of the prong 22 in the longitudinal direction, specifically the vertical distance from the base 26 to the highest point or segment. However, the depth of the cell 76 is about 70 times the diameter of the cell 76.
As the percentage increases, the length dimension of the prongs 22 remains substantially constant. This is because not all of the liquid prong material is withdrawn from cell 76 and deposited on substrate 24. Due to the surface tension and viscosity of the liquid prong material, some of this material remains in the cells 76 and is not transferred to the substrate 24.

For the example described herein, about 50 diameters
A substantially cylindrical blind cell 76 having a depth of between 70% and 70% is suitable. If desired, the cell 76 may be tapered to a somewhat frusto-conical shape to accommodate conventional manufacturing methods such as chemical etching.

If frusto-conical, the included angle of the taper of the cell 7 should not exceed about 45 ° to form the shank 28 with the preferred taper and obtain the above-mentioned ratio for the highest height of the base. If the included angle of the taper of the cell 76 is larger than this, a prong 22 having an excessively large taper is formed. If the included angle is too small, or if the cell 76 is cylindrical, a shank 28 with a substantially uniform cross section is formed, thereby having a high stress region. For the embodiment described herein, the included angle is about 45 ° and the diameter around the roll is about
0.89mm to about 1.22mm (0.035 inch to 0.048 inch)
With a depth of about 0.25 mm to about 0.51 mm (0.01 inch to 0.02
Inch cells 76 form suitable prongs 22.

The print roll 72 and the receiving roll 74 are sufficient to extrude the adhesive from the cells 76 of the print roll 72 onto the substrate 24 and to drive the opposing roll if it is not driven externally. In order to provide frictional engagement, these rolls must be compressed in line with the line connecting the centerlines. Receiving Roll 74 Prints Prong Material
When deposited from 72 onto substrate 24, it must be somewhat softer and more flexible than printing roll 72 to provide cushioning of the prong material. A receiving roll 74 having a rubber coating having a Shore A durometer of about 40 to about 60 is suitable. Rolls 72 and 74 may be pressed together with a force such that a dip in the machine direction of about 0.25 inch to about 0.50 inch is obtained. As used herein, the term "indentation" relates to the contact area of a soft roll on a substrate 24 as the substrate 24 passes through the nip 70.

The print roll 72 is preferably heated to prevent solidification of the prongs 22 during transfer by depositing it on the substrate 24 from a material source. Generally, it is desirable that the surface temperature of the print roll 72 be close to the temperature of the material at the source. About 197 of the polyester hot melt adhesives sold by Bostic Shank of Middleton, Mass.
The printing roll 72 at a temperature of ° C. was found to be excellent.

It will be appreciated that if the substrate 24 is adversely affected by the heat transferred from the prong material, a chill roll is required. If a chill roll is desired, the chill roll can be cooled using a means known to those skilled in the art.
It is good to be incorporated in. This equipment is required if a polypropylene, polyethylene, or other polyolefin substrate 24 is used.

The materials used to form the individual prongs 22
Prongs 22 must be maintained in a material source that provides the proper temperature for applying to substrate 24. Typically,
A temperature slightly above the melting point of the material is desirable. A material is considered to be at or above the "melting point" if part or all of it is liquid. If the source of the prong material is kept too hot, the viscosity of the prong material will not be sufficient and the engagement means 30 will couple laterally to the adjacent prong 22 in the machine direction. If the temperature of the material is too high, the prongs 22 will flow into small, somewhat hemispherically shaped paddles and no engagement means 30 will be formed. Conversely, if the temperature of the material source is too low, the prong material cannot be transferred from the material source to the means for depositing the material, and therefore will be properly transferred from the deposition means 76 to the substrate 24 in the desired array or pattern. Cannot be transferred to The material source must provide the material with a temperature distribution that is substantially uniform transverse to the machine direction, must be in communication with the means for depositing the adhesive material on the substrate 24, and It must be easy to refill or replenish the material when it is empty.

A suitable source of material is trough 80, which is
It has a 76 and is substantially co-extensive with the portion of the printing roll 72 transverse to the machine direction adjacent to the trough 80. The top may be open or closed as desired.
The inside of the trough 80 is open, so that the liquid material in the trough can freely contact and communicate around the printing roll 72.

The material source is externally heated by known means (not shown) to keep the prong material in a liquid state and at an appropriate temperature. The preferred temperature is above the melting point, but below this temperature a large loss of viscoelasticity occurs. If desired, the trough is used to increase homogeneity and temperature distribution.
The liquid material in 80 may be mixed or circulated.

At the bottom of the trough 80, a doctor blade 82 for controlling the amount of the prong material applied to the printing roll 72 is juxtaposed. The doctor blade 82 and the trough 80
Retained stationary during the rotation of the 72, the doctor blade 82 wipes around the roll 72, scrapes any prong material that did not enter the individual cells 76 from the roll 72, and allows such material to be recycled . With this configuration,
Prong materials can be applied from the cells 76 to the substrate 24 in a desired array according to the shape of the cells 76 around the print roll 72. As can be seen in FIG. 4, the doctor blade 82 is preferably arranged in a horizontal plane, in particular at the horizontal top of the printing roll 72 upstream of the nip point 70.

Cutting means for cutting the prongs 22 and moiring with the engaging means of the fastening system 20 after being deposited on the substrate 24
At 78, the prongs 22 are cut from the print roll 72 and the attachment means. As used herein, the term “moile” relates to any material that is cut from the prongs 22 and does not form part of the fastening system 20.

The cutting means 78 must be adjustable to accommodate the various sized prongs 22 and lateral protrusions 38 of the engaging means 30 and to even out the array transversely to the machine direction. Must. The term "cutting means" relates to means for longitudinally separating the moil from the fastening system 20. The term "cutting" relates to the action of splitting the moile from the fastening system 20 as described above. The cutting means 78 must be clean and must not rust and must not oxidize the prongs 22 or impart any corrosive or contaminant (such as moir) to the prongs 22. Suitable cutting means are positioned substantially parallel to the axis of the rolls 72 and 74 and are spaced from the highest height of the solidified prongs 22 by a distance somewhat greater than the vertical distance from the base 24 to the substrate 24. Wire.

Preferably, the wire 78 accommodates the cooling of the prongs 22 that occurs between the time the prong material leaves the heated source of prong material and the time the cutting is performed, and encourages the lateral extension of the engagement means 30, Cutting means 78 for molten prong material
Heated by electricity so as not to deposit on top.

Furthermore, the heating of the cutting means 78 must be performed so as to even out the temperature distribution transverse to the machine direction, so that an array of prongs 22 having a substantially uniform shape is formed.

In general, as the temperature of the prong material increases, the temperature of the relatively low temperature hot wire temperature cutting means 78 can be applied. In addition, as the speed of the substrate 24 is reduced, the cooling of the hot wire 78 that occurs when cutting the prong 22 and the foil is performed less frequently, thereby providing a relatively low wattage hot at the same temperature. Wire 78 can be used. Hot wire
It should be understood that increasing the temperature of 78 results in prongs 22 having an overall shorter shank 28 length.
Conversely, the length of the shank 28 and the lateral length of the engagement means 30 increase in an inverse relationship as the temperature of the hot wire 78 decreases. The cutting means 78 need not actually contact the prongs 22 to make the cut. The prongs 22 are preferably cut by radiant heat emitted by the cutting means 78.

For the embodiment described herein, the diameter is about 0,0.
A circular cross-section nickel-chrome wire 78 heated to about 343 ° C. to about 416 ° C., 51 mm (0.02 inches) has been found to be suitable. The knife, laser cutting means or other cutting means 78 may be replaced by the hot wire 78 described above.

It is important that the cutting means 78 be positioned such that stretching of the prong material occurs before cutting the prongs 22 from the foil. If the cutting means 78 is too far from the plane of the substrate 24, the prong material will pass under the cutting means 78 and will not be trapped by the cutting means, forming a very long engagement means 30 . This engagement means is not properly spaced from the substrate 24 or adjacent prongs 22. Conversely, if the cutting means 78 is too close to the plane of the substrate 24, the cutting means 78 will cut the shank and
30 cannot be formed.

For the manufacturing method disclosed herein, the nip point
Approx. 14mm to 22mm in machine direction from 70 (0.56 inch to 0.88
Inches), preferably about 18 mm (0.72 inches) and about 4.8 mm to 7.9 mm (0.19 inches to 0.31 inches) from the receiving roll 74, preferably about 6.4 mm (0.25 inches) and radially outward from the printing roll 72. About 1.5 mm to 4.8 mm (0.06 inch to 0.19 inch), preferably about 3.3 mm (0.13 inch)
The cutting device 78 made of a high-temperature wire disposed at the position is appropriately positioned.

In operation, the substrate 24 is transferred in a first direction relative to the attachment means 76. More specifically, substrate 24 is transported through nip 70 and is preferably withdrawn by a take-up roll (not shown). This provides a clean area of the substrate 24 for continuously attaching the prongs 22 and removing the portion of the substrate 24 to which the prongs 22 have been attached. A direction substantially parallel to the main transport direction of the substrate 24 when the substrate 24 passes through the nip 70 is referred to as a “machine direction”. The machine direction indicated by the arrow 75 in FIG. 4 is substantially perpendicular to the center lines of the printing roll 72 and the receiving roll 74. A direction substantially orthogonal to the machine direction and parallel to the plane of the base material 24 is referred to as “lateral to the machine direction”.

Substrate 24 may be pulled through nip 70 at a speed of about 2% to about 10% greater than the surface speed of rolls 72 and 74. This prevents the substrate 24 from bunching or wrinkling near the means 78 for cutting the prongs 22 from the means for depositing the prong material on the substrate 24. The base material 24 is about 3 m / min to about 31 m / min (1 minute / minute).
(0 feet to 100 feet) through the nip 70 in the first direction. The speed at which the substrate 24 is transported through the nip 70 can affect the angle of the shank 28. If a prong 22 with a shank angle α closer to the normal to substrate 24 is desired, a slower transport speed of substrate 24 in the first direction is selected. Conversely, increasing the transfer speed reduces the angle α of the shank 28, resulting in an engagement means 30 having a larger lateral protrusion 38.

In order to properly orient the engagement means 30 laterally and longitudinally using the viscoelasticity of the prong material, the substrate 24 may be moved from the plane of the nip 70 to
It is preferable to incline at an angle γ of ゜ to 55 °, preferably 45 °. In addition, this configuration provides even greater force for withdrawing the prong material from the cell 76 and withdrawing it from the print roll 72. If it is desired that the angle α of the shank 28 be small, then the angle γ from the plane of the nip 70 must be reduced. Furthermore, increasing the angle γ away from the plane of the nip 70 has a weak but positive effect in forming the engagement means 30 with a large lateral protrusion 38.

After depositing the prong material from the cell 76 onto the substrate 24,
Rolls 72 and 74 continue to rotate in the direction indicated by arrow 75 in FIG. This provides a relative movement period between the transferred substrate 24 and the cell 76, during which time (before cutting) the prong material bridges the substrate 24 and the printing roll 72. During relative movement,
The prong material is stretched until a cut is made to separate the prongs 22 from the cells 76 of the printing roll 72. As used herein, the term "stretch" means an increase in linear dimension, at least a portion of which is substantially permanent over the life of the fastening system 20. Become.

As discussed above, it is also necessary to cut individual prongs 22 from print roll 72 as part of the method of forming engagement means 30. When cutting, prong 22
Is cut in two parts, the fastening system 20
The length is divided into a distal end and engagement means 30 remaining on the print roll 72 and a moil (not shown) remaining on the print roll 72 and recycled as desired. After cutting the prongs 22 from the moil, the fastening system 20 is allowed to solidify before the prongs 22 come into contact with other objects. After the prongs 22 have solidified, the substrate 24 may be wound into a roll for storage as desired.

In a non-limiting example of the method, the prong material is placed in trough 80 and heated to a temperature slightly above the melting point in a manner well known to those skilled in the art. If a hot melt adhesive of polyester resin is selected, about 177 ° C. to 193 ° C., preferably 186 ° C.
Has been found to be suitable.

When a polyamide resin is selected, the temperature is about 193 ° C to 213 ° C.
C., preferably 200.degree. C., has been found to be suitable. Substrate 24 made of bleached kraft paper on one side and having a thickness of about 0.008 mm to about 0.15 mm (0.003 inch to 0.006 inch) is excellent with hot melt adhesive prongs 22. The prongs 22 are joined to the bleached side of the kraft paper substrate.

For the exemplary operation described herein, about 26 cells 76 per cm ² (169 cells 7 per square inch)
6), about 5 cells 76 (1 cm) in both the machine direction and the machine direction.
Printing rolls 72 having an array of 13 cells 76) per inch are suitable. This grid density can be used advantageously with a printing roll 72 having a diameter of about 16 cm (6.3 inches) with cells 1 mm (0.045 inches) in diameter and 0.8 mm (0.030 inches) deep. This print roll 72 has about 15.2cm
A vertically aligned receiver roll 74 having a diameter of (6.0 inches) has been found to be superior. The transfer speed of the substrate 24 is about 3.0 m / min (10 feet per minute).

About 18 mm (0.72 inch) in the machine direction from the nip point 70, about 0.3 mm (0.13 inch) radially outward from the printing roll 72, and about 6.4 mm (0.25 inch) radially outward from the receiving roll 74
A nickel-chromium high-temperature wire 78 having a diameter of about 0.5 mm (0.02 inch) disposed in inches is heated to a temperature of about 382 ° C. The fastening system 20 formed by this operation is substantially similar to the fastening system shown in FIG. 1 and advantageously incorporates the fastening system 20 into the exemplary articles discussed below.

Without being bound by any particular theory, the shape of the engagement means 30 depends on the elasticity of the hot melt adhesive used to form the prong 22 and the distance between the trailing edge 46 and the leading edge 42 of the prong 22 It is considered that it depends on the temperature difference. Prong 22
The trailing edge 46 is shielded, ie insulated, from the heat generated by the cutting means 78. Conversely, the leading edge 42 is directly exposed to the heat of the cutting means 78 so that the leading edge 42 solidifies or solidifies after the trailing edge 46 solidifies or solidifies. This causes the leading edge 42 to stretch relatively to the trailing edge 46 and cause the trailing edge 46 to contract relative to the leading edge 42. If this temperature difference is large, a relatively long engagement means 30 is formed.

If desired, a relatively very small prong 22 can be formed by forming a natural pattern from the print roll 72.
(Not shown). As used herein, the term “natural pattern” refers to the cell 76
Prongs 22 formed by a printing roll 72 which does not have
Of the array. Thus, the pattern of the prongs 22 has a gap between the doctor blade 82 and the printing roll 72,
And to a lesser extent, the surface finish of the print roll 72.

The doctor blade 82 forms a natural pattern that must be adjustable so that the radial gap from the print roll 72 forms a gap of about 0.03 mm to about 0.08 mm (0.001 inch to 0.003 inch), The very small prongs 22 obtained from such a printing roll 72 are used with a reticulated foam receiving surface that has no strands or openings between the strands but undergoes local elastic deformation that resists separation of the fastening system 20. .

Referring to FIG. 5, if a more isotropic fastening system 20 "in peel strength is desired, the fastening system 20 of FIG. It is preferable to form a simple fastening system 20 ″. As shown in FIG.
The fastening system 20 of FIG. 1 is further processed to form a shank 28 having engagement means 30 "extending radially from the shank 28". The term "random orientation" means that the lateral projection 38 "and the outline have a significantly different orientation than the adjacent prongs 22".

Without being bound to any particular theory, this structure is created by creating a temperature difference between the outer or leading edge surface 42 and the trailing edge surface 46 of the prongs 22 of the fastening system 20 of FIG. It is believed that such a temperature difference is formed, which may be increased by radiation or, preferably, by convection.

In addition, due to the temperature difference between the leading edge surface 42 ", ie, the outer surface, and the trailing edge surface 46", the engagement means 30 "has a lateral projection 38".
The orientation of the prongs 22 "can be significantly altered, or reversed, to form prongs 22" oriented in a direction other than the direction in which it was first cooled or solidified. It may be created by any temperature difference source known to those skilled in the art, which is preferably located above the prongs 22 ", which can provide the indicated temperature difference to the fastening system 20". Airgun 84
It is.

The temperature difference source for providing the indicated temperature difference desirably directs the air flow to the fastening system 20 '' within about ± 90 ° of the first direction of the substrate 24 '', which is the machine direction. As used herein, "about ± 90 in the first direction.
The term “゜” means a direction having a vector component substantially perpendicular to or opposite to the first movement direction of the substrate 24 ″, and includes a direction substantially opposite to the first movement direction.

The substrate 2 is provided with a temperature difference source 84 for giving the indicated temperature difference.
When positioned at an angle of about 180 ° with respect to the first direction of travel of the 4 ″, the temperature difference source 84 will cause the prongs of the fastening system 20 ″ to move.
22 "is directed toward leading edge surface 42", i.e., in a direction substantially opposite to the machine direction of the method described and claimed herein. When the temperature difference source 84 is directed directly toward the leading edge surface 42 "of the prong 22", the lateral protrusion of the engagement means 30 "
38 rotates to change the orientation of the lateral protrusion by about 180 °. Prongs 22 "located somewhat lateral to the temperature difference source 84 to provide the indicated temperature difference, i.e., transverse to the machine direction.
Does not rotate the engagement means 30 by 180 °, but instead rotates the engagement means 30 ″ by about 90 °, thus providing the indicated temperature difference oriented transverse to the machine direction. A temperature difference source 84 provides a fastening system 20 "having prongs 22" having various lateral orientations transverse to the machine direction according to the position of the prongs 22 "relative to the temperature difference source.

Approximately 88 inches at a distance of approximately 46 cm (18 inches) from the substrate 24 ″
An air gun 84 that discharges air at a temperature of ° C. is a suitable temperature difference source. The 133-348 series sold by Dayton Electric of Chicago, Ill., Oriented at an angle of about 45 ° to the plane of the substrate 24 ″ and positioned about 46 cm (18 inches) from the prongs Is a fastening system having a pattern substantially the same as the pattern shown in FIG.
20 ". One or more hot wires positioned above the prongs 22" and oriented in the machine direction are provided with engagement means 30 "oriented transverse to the machine direction.
It will be apparent to those skilled in the art that the fastening system 20 "is formed with a regular, somewhat striped pattern.

Without being bound by any theory, the temperature of the air exhausted from the temperature difference source 84 to provide the indicated temperature difference is less than the temperature around the outer surface of the prong 22 "or the leading edge 42". It is believed that the change in orientation of the engagement means 30 "that occurs in some cases is caused by the cooling of such an outer surface or leading edge surface 42" with respect to the trailing edge surface 46 ". Causes shrinkage of the portion of the prong 22 "to which the temperature difference source 84 is directed. This contraction
Cooling the leading edge 42 "with a temperature difference relative to the trailing edge 46" causes a change in orientation of the engagement means 30 "and the lateral protrusion 38". Without being bound by another theory, the release of residual stresses occurring during cooling affects the change in orientation of the lateral protrusion 38 ".

It will be apparent to those skilled in the art that other variations are possible. For example, the engaging means 30 may form the prong 22 protruding in one or more directions, or the free-form prong 22 may be formed by a known method other than gravure printing. If desired, only one roll may be used in the manufacturing process and the substrate 24 may be contacted over at least about 180 ° around the roll.

It is often desirable to provide a fastening system 20 of the present invention in which the maximum lateral protrusion 38 of the prong 22 is oriented in a direction other than the machine direction. For example, when using the present invention as a fastening means for a disposable diaper, it is desirable that the maximum lateral protrusion 38 of the prongs 22 be oriented substantially perpendicular to the direction of travel of the disposable diaper on a production line. If the maximum lateral protrusion 38 of the prongs 22 is oriented in the machine direction, the diaper production line requires complex and expensive substrates to cut, reorient, and install the fastening system 20 . However, the fastening system 20 of the present invention, manufactured with the maximum lateral protrusion 38 of the prong 22 oriented transverse to the machine direction, does not require reorientation prior to attachment to a disposable diaper. Therefore, the maximum lateral protrusion 38 of the prong 22
The ability to manufacture a fastening system 20 of the present invention in which is oriented in a direction other than the machine direction is a very significant advantage.

Prong 22 shank 28 formed by this method
There are two angles that make up. The shank 28 forms an angle α with the plane of the substrate 24, as discussed above,
Azimuth with respect to the machine direction of the substrate 24 (reference numeral A in FIG. 7)
). As used herein, the term "azimuth" refers to the angle, when viewed from above, that the largest lateral protrusion 38 comprises with respect to the machine direction of the substrate. As used herein, the term “viewed from above” refers to viewing the prongs 22 from a direction perpendicular to the plane of the substrate 24. The term "machine direction" refers to a direction generally parallel to the main transport direction of the substrate 24 as it passes through the nip 70, and is referred to in FIG.
Indicated by Azimuth is measured by first determining the maximum lateral protrusion 38 of the prong 22 as disclosed above. As shown in FIG. 7, the azimuth indicated by the reference character A is the angle with respect to the machine direction defined by a line 60 drawn parallel to the maximum lateral protrusion 38 when viewed from above. The azimuth A can be measured either clockwise or counterclockwise with respect to the machine direction.
Do not exceed 0 ゜. A fastening system 20 suitable for use in a disposable diaper preferably includes a prong 22 having an azimuthal angle such that the maximum lateral protrusion 38 is oriented in a predetermined direction having a vector component perpendicular to the machine direction of the substrate 24. It has.

Thus, the prongs 22 are between about 1 mm and about 18 mm above 0 mm.
It should have an azimuth of 0 °, which is typically around 20 °.
More than ゜ (20 ゜ -180 ゜), more than about 45 ゜ (45 ゜ -180)
゜) or about 60 ° or more (60 ° to 180 °). The azimuth of the prongs 22 formed by the method described herein is:
Preferably from about 20 ° to about 160 °, more preferably from about 45 ° to about 135 °, and most preferably from about 60 ° to about 135 °.
゜ to 120 ゜. In the preferred embodiment shown in FIG. 7, the azimuth of the prongs 22 is approximately 90 degrees.

A method for imparting azimuth to fastening system 20 is to press on prongs 22 of fastening system 20 when prongs 22 are partially or wholly liquid. As used herein, the term "pressing" refers to the application of force or
It relates to a means for affecting a direction having a vector component perpendicular to 24 machine directions. Prong 22 consists of these newly formed prongs, not yet cooled or solidified,
It can be pressed when there is fluidity, or by reheating the prong 22 after it has cooled and solidified, and bends when pressed. Many methods are available for pressing the prongs 22 to create an azimuth.

A suitable method for azimuth angle is when the prongs are partially or wholly liquid, the gravity
Pressing the prongs 22 by applying gravity to the prongs 22 to pull the prongs 22 to the desired azimuthal angle. This is done by tilting the substrate 24 so that the plane of the substrate 24 does not intersect perpendicularly with the plum line when viewed in the machine direction, but forms an angle other than 90 ° with the plum line. When printing and cutting the prongs 22, the angle of the substrate 24 relative to the horizontal, indicated by reference H in FIG. 8, causes gravity to act on the distal end of the shank 28 and the engagement means 30,
Pull towards the lower longitudinal side of the 24. Preferably, the printing roll 72 and the receiving roll 74 are tilted or raised at one end from the horizontal, as shown in FIG. 8, so that when the substrate 24 passes through the nip 70 of these rolls, The height of the longitudinal edge of the base material 24 is different,
The gravity indicated by reference G in FIG. 8 acts on the prongs 22 to provide an angle α and an azimuth A of the shank 28 with respect to the substrate 24 (FIG. 8 shows neither angle α nor A). twenty four
Must be inclined such that the plane of the substrate 24 forms an angle of at least about 15 ° with the horizontal. Preferably, the plane of substrate 24 is at an angle of at least 30 °.

A non-limiting example of a method is Bostic polyester hot melt adhesive # 7199, heated to a temperature of about 197 ° C (3870F), having a diameter of 0.040 inches and a depth of 0.140 inches.
177 ° C. (350 ° C.) with 0.046 cm (0.018 inch) cell 76
0F) printing roll 72 heated to a temperature of 0.08m per square meter
A substrate made of white kraft paper having a basis weight of 4.66 m / min (14 feet per minute) and a printing roll 72 and a receiving roll 74 inclined at an angle of about 30 ° with respect to the horizontal direction are provided. Good to use.

Other suitable methods for providing azimuth include prong 22
When is partially or wholly liquid, a pressure differential is applied across the plane of the substrate 24 such that these prongs 22 are forced to or pulled at the desired azimuthal angle. Pressing the prongs 22. This can be done by flowing a gas or liquid across the plane of the substrate 24 in a direction having a vector component perpendicular to the machine direction. The prongs 22 are bent or redirected toward the low pressure side of the substrate by the pressure difference. Preferably, the pressure differential across the substrate 24 is obtained by creating a high pressure on one side of the substrate 24 using an air jet, air needle, or other means known in the art. However, the pressure differential across the substrate 24 may be obtained by creating a low pressure (ie, vacuum or partial vacuum) on one side of the substrate 24, creating a high pressure on one side of the substrate 24, It may be obtained by creating a low pressure on the other side of the material 24. The side of the substrate 24 that provides the high or low pressure side, and the angle at which the fluid flows relative to the machine direction, will vary depending on the desired azimuthal angle. The fluid medium used is preferably air, but other gases and liquids may be used. As used herein,
The term "high pressure" is used when prongs
Regarding a pressure higher than the ambient pressure of the air or other fluid surrounding 22. As used herein, the term "low pressure" refers to a pressure that is lower than the ambient pressure of the air or other fluid surrounding the prongs 22 when azimuthed.

It should be understood that the high pressure source and / or the low pressure source are appropriate other than on the sides of the substrate 24. That is, the high pressure source and / or the low pressure source are positioned such that the prongs 22 are pushed and / or pulled in one or more directions to form a fastening system 20 with greater isotropic peel strength. Is good. As a non-limiting example, the vacuum source may be positioned near the sides of the substrate 24 such that the maximum lateral protrusion 38 of the prongs 22 is significantly affected as moving away from the center of the substrate 24 toward the sides of the substrate 24. And the pressure source is preferably located near the center of the substrate 24.

If a pressure differential is used to azimuth the prongs 22, turbulence in the selected fluid medium will often scatter or undesirably azimuth some of the prongs 22. Happens. To avoid scattering of the prongs 22, it is desirable to eliminate turbulence in the fluid medium and to maintain a streamlined or laminar flow. Many methods are available for creating a substantially laminar flow.

One way to create a substantially laminar flow is to control the flow direction using one or more nozzles or flow amplifiers. As a non-limiting example, two commercially available air fluid amplifiers 902 are used in conjunction. A first airflow amplifier 902 (labeled P in FIG. 9) has its outlet discharge flow directed across the substrate 24. A second airflow amplifier 902 (labeled V in FIG. 9) draws across its substrate 24 with suction at its inlet. By drawing the exhaust stream of the first airflow amplifier P into the inlet of the second airflow amplifier V, a substantially linear ventilation is created. The airflow amplifier 902 is oriented with respect to the substrate 24 so as to create low-speed, linear ventilation transverse to the machine direction. The preferred location for straight ventilation is immediately downstream of the cutting hot wire 78 (not shown in FIG. 9). By using an enclosure to surround the area where straight ventilation is applied, abnormal airflow can be eliminated. A suitable airflow amplifier is
Transformer vector 912/9, commercially available from Voltech of Cincinnati, Ohio and rated from 25 to 100 SCFM
Sold as Model 52. The required air pressure can be changed, but it is about 0.0703kg / cm2 to 0.703kg / cm2 (1ps
i. to 10 psi.).

Another suitable method for angling the prongs 22 is to press the prongs 22 by mechanically bending or physically pulling when the prongs 22 are partially or wholly liquid. is there. A non-limiting example of this method is to push or pull the prongs 22 to a desired azimuthal angle when cutting the prongs 22 by rocking or rotating a cutting means, for example, a hot wire (not shown). There are many other ways to do this, and these methods will be apparent to those skilled in the art.

It should also be understood that the prongs 22 can be azimuthalized by using a combination of methods of pressing the prongs 22. A non-limiting example using a combination of methods azimuths the prongs 22 using a combination of gravity and the pressure difference across the plane of the substrate 24. Another non-limiting example uses a combination of gravity and rotary cutting means to attach an azimuth to the prongs 22. Many other ways to azimuth the prongs 22 as well as various other combinations will be apparent to those skilled in the art.

Illustrative Article of Use Fastening system 12 of the present invention in the manufacture of an article
An illustrative, non-limiting example of the use of 0 is described below. This is shown in FIG. Mechanical fastening systems have been advantageously used in disposable absorbent articles disclosed in U.S. Patent Application Serial No. 07 / 132,281 Publication No. N97, filed on December 18, 1987 under the name of Scripps. Diapers
For purposes of illustrating the advantageous use of the structure 120 in such a diaper with the structure of 110 and the mechanical fastening system 20, reference has been made to the same patent application, the contents of which are hereby incorporated by reference. It shall be incorporated into.

For example, it is known that the mechanical fastening system 120 is less easily soiled with oil or powder than the adhesive tape fastening system, and that it can be easily reused. All of these features
It provides advantages when applied to disposable diapers 110 intended for use by infants. In addition, the refastenable fastening system offers the advantage that the infant can be checked to see if the disposable diaper 110 has become soiled during wear.

Referring to FIG. 6, there is shown a disposable diaper 110 adapted for a child to wear around the lower limbs. As used herein, the term "disposable absorbent article" generally refers to garments worn by infants or incontinent persons, the garments being pulled between the legs and around the wearer's torso. It is stopped after use and is to be discarded after one use, and is not intended to be washed or recycled. "Disposable diapers" are certain disposable articles that are intended to be worn by infants and are sized.

Preferred diapers 110 include a liquid-permeable top sheet 112, a liquid-impermeable back sheet 116, and top sheet 112 and back sheet.
It has an absorber core 118 in between. The upper sheet 112 and the rear sheet 116 hold the core 118 at a predetermined position,
At least a part of the periphery is joined. The elements of the diaper 110 can be assembled into various configurations known to those skilled in the art, and preferred configurations are outlined in US Pat. No. 3,860,003, issued Jan. 14, 1975 to Buell.
For the purpose of disclosing a particularly preferred form of diaper 110,
By reference to this patent, the disclosure of that patent is hereby incorporated by reference.

The upper sheet 112 and the rear sheet 116 of the diaper 110 are entirely coextensive, and at least a part of the periphery is joined to each other as described above. The joining of the top sheet 112 and the back sheet 116 may be accomplished with a hot melt adhesive such as East Bond A3 manufactured by Eastman Chemical Company of Kingsport, TN. The length and width of the absorber core 118 are smaller than the length and width of the upper sheet 112 and the rear sheet 116 as a whole. The core 118 is interposed in a fixed relationship between the upper sheet 112 and the rear sheet 116.

The perimeter of the diaper 110 has first and second ends 122 and 124 disposed opposite each other. Diaper 110, Diaper 1
The diaper 110 extends from a first end 122 and a second end 124 around the diaper 10.
About 1/5 of the length of the diaper 110 toward the lateral center line of
A first torso portion 142 and a second torso portion 144 each extending 1/3 of the distance
Having. These torso portions 142 and 144 comprise the portion of the diaper 110 that surrounds the wearer's torso when worn and are at the highest height of the diaper 110 when the wearer is in an upright position. The crotch 146 of the diaper 110 is the diaper 10
0, which is disposed between the first torso portion 142 and the second torso portion 144, and is positioned between the legs of the wearer when worn.

An absorbent "core" is any means for absorbing and retaining body exudates. The absorbent core 118 is generally compressible, easily conforms to the outer shape, and does not irritate the wearer's skin. A preferred core 118 has first and second sides and is further surrounded by a tissue layer, if desired. One of both faces of the core 118 faces the upper sheet 112, and the other face is oriented toward the rear sheet 116.

Absorber core 118 is overlaid on backsheet 116 and is preferably joined to the backsheet by means well known in the art, such as by gluing. In a particularly preferred embodiment, adhesive bonding is performed with a longitudinal adhesive strip that joins the core 118 to the backsheet 116. Rear seat 11
6 is impervious to liquids so that the liquids absorbed and contained within the absorbent core 118 do not wet the underwear, clothing, bed, and any other articles in contact with the diaper 110 I do. As used herein,
The term “back sheet” refers to the core 1 when the diaper 110 is worn.
Regarding any barrier located outside of 18, this will contain the absorbed liquid in the diaper 110. Preferably, the backsheet 116 is a polyolefin film having a thickness of 0.012 mm to 0.051 mm (0.0005 inches to 0.002 inches). Polyethylene films are particularly preferred, suitable films are manufactured by Monsanto of St. Louis, Mo. as Film No. 8020. If desired, the backsheet 116 may be embossed or matte to provide a garment-like appearance, or have a passageway to allow vapor to escape.

The topsheet 112 is soft, has a pleasant tactile sensation, and is non-irritating to the wearer's skin. The upper sheet 112 has an absorbent core 118
And the liquids therein do not come into contact with the wearer's skin. The upper sheet 112 is liquid permeable so that liquid can easily penetrate therethrough. As used herein, the term “top sheet” refers to a liquid permeable surface that comes into contact with the wearer's skin when the diaper 110 is worn, and
Ensure that 118 does not come into contact with the wearer's skin. Upper sheet 1
The 12 may be made of a woven, non-woven, spunbonded, or carded material. The preferred topsheet 112 is carded and thermally bonded by means well known to those skilled in the art of nonwovens. Particularly preferred topsheet 112 has a weight of about 18 g to about 25 g / m2, a minimum dry tensile strength in the machine direction of about 400 g / cm, and a wet tensile strength transverse to the machine direction of at least. It is about 55g per cm.

The diaper 110 includes a first torso portion 142 and a second torso portion 144 so that the diaper 110 is fixed to a wearer when the diaper 110 is worn.
A fastening system 120 and a receiving surface 153 are provided for maintaining the two in a superposed configuration. Thus,
When fastening system 120 is secured to receiving surface 153, diaper 110 can be worn on a wearer and can form a side closure.

Fastening system 120 must resist the separation forces that occur during wear. The term "separation power"
Separation of the fastening system 120 from the receiving surface 153,
Causes release or removal. Fast nig system
120 and the force acting on the receiving surface 153. The separation power is
Includes both peel and shear forces. The term “shear” relates to a splitting force acting substantially tangentially on the receiving surface 153 and can be considered to be substantially parallel to the surface of the substrate of the fastening system 120. The term "peeling force" refers to a generally longitudinal and receiving surface 153.
And the dividing force applied perpendicularly to the substrate of the fastening system 120.

The shear force is applied to the fastening system 120 and the receiving surface 153
Are pulled in opposite directions substantially parallel to the plane of the respective substrate. A method for determining the resistance of the fastening system 120 and the receiving surface 153 to shear is described in further detail in U.S. Patent No. 4,699,622, issued to Tozan et al. On October 13, 1987. For purposes of illustrating the measurement of shear forces, reference is made to the patent, and the disclosure of that patent is incorporated herein.

Peel force is measured by pulling the fastening system 120 from the receiving surface 153 at an angle of about 135 °. Methods for determining the resistance of the fastening system 120 and the receiving surface 153 to peeling force are described in November 1987.
U.S. Patent Application No. 07 filed on the 18th in the name of Scripps
/ 132,281 issue N87.
For the purpose of explaining the measurement of the peeling force, the contents disclosed in the patent application are incorporated herein by referring to the patent application.

The separation force is typically determined by the movement of the wearer,
Or, when the wearer tries to remove the diaper 110. In general, infants should not be able to remove the fastening system or remove the diaper 110 they are wearing, nor should the diaper 110 be released in the presence of the normal separation forces that occur during normal wear. However, it must be removable by an adult to change the diaper when it becomes dirty or to check if the diaper has been soiled. Generally, the fastening system 120 and the receiving surface 153 weigh at least 200 g, preferably at least about 500 g, and more preferably at least about 700 g.
Must resist the peeling force of Further, the fastening system 120 and the receiving surface 153 are at least
It must resist a shear force of 500 g, preferably at least about 750 g, more preferably at least about 1000 g.

The receiving surface 153 is located at any first position on the diaper 110 as long as the receiving surface 153 engages the fastening means to maintain the first and second torso portions 142 and 144 in an overlapping configuration. Is good. For example, the receiving surface 153 may include a second
It may be located on the outer surface of the torso portion 144, on the inner surface of the first torso portion 142, or at any other location on the diaper 110 that is arranged to engage with the fastening system 120.
The receiving surface 153 may be integral, may be a separate transverse direction joined to the diaper 110, or the upper sheet 11
It may be a single piece of material that is not discontinuous, such as two or the back sheet 116, which is separated from the lateral direction of the diaper 110.

Although the receiving surface 153 can take a variety of sizes and shapes, the receiving surface 153 is preferably the outer surface of the second torso portion 144 to allow for maximum adjustment of the wear on the wearer's torso. Consisting of one or more integral patches positioned over the entire patch. As shown in FIG. 6, the receiving surface 153 is preferably an elongated rectangular shaped integral member secured to the outer surface of the second torso portion 144.

A suitable receiving surface 153 is a non-woven, stitch-bonded or any other type of fiber or loop material known in the art. Receiving surface 153
Can be made from a variety of materials that provide a fiber element and, preferably, a loop that can be captured and retained by the engagement means. Suitable materials include nylon, polyester, polypropylene, and combinations thereof. A suitable receiving surface 153 has a number of fiber loops protruding from the woven fabric and is commercially available as ScotchMate trademark nylon fabric loop No. FJ3401 sold by 3M Company of St. Paul, Minn. Another suitable receiving surface 153 comprises a tricot having a plurality of nylon filament loops projecting from a nylon backing. It is commercially available from Guildford Mills, Inc. of Greensboro, North Carolina and is labeled Guildford 16110. A particularly preferred receiving surface 153 is a stitch bonded loop material sold under the number 970026 from Milliken Company of Spartanburg, South Carolina.

The fastening system 120 is adapted to engage the complementary receiving surface 153 to provide a secure mounting of the diaper 110. The fastening system 120 may be any of the known configurations used to provide a side closure to the disposable diaper 110. The substrate of the fastening system 120 is bonded to the diaper 110 in a spaced relationship from the receiving surface 153. As shown in FIG. 6, the fastening system 120 is preferably such that the first and second lengths of the diaper 110 are located on both directional sides. The preferred configuration for the fastening system 120 ensures that there is no contact between the prongs of the fastening system 120 and the wearer's skin. Preferred fastening system
The configuration of the 120 is a Y-shaped tape, November 19, 1974
This is described in more detail in U.S. Pat. No. 3,848,594, issued to Buell on a date. An alternative preferred fastening system 120 configuration is described in detail in U.S. Pat. No. 4,699,622, issued to Tozan et al. On Oct. 13, 1987.

For purposes of illustrating various arrangements of the fastening system 120 on the disposable diaper 110, reference is made to these patents, the contents of which are incorporated herein.

The fastening system 120 of FIG.
56 and the opposite user end 158. The manufacturer's end 156 is preferably in a juxtaposition with the first torso 142
Joined to 110. The user's end 158 is a free end, and when securing the diaper 110 to the wearer, the receiving surface 153
Fixed to

After the diaper 110 is worn around the wearer's torso, the user's end 158 of the fastening system 120 is received on the receiving surface 153.
And is preferably disposed on the second torso portion 144 such that the diaper 110 surrounds the wearer's torso. The diaper 110 affects the side closure.
The prongs (not shown) engage the user's end 1 so as to catch the strands of the receiving surface 153.
Extends from 58 fastening systems 120.

The fastening system 120 and the complementary receiving surface 153 that resist peeling forces in excess of 700 g and shear forces in excess of 1000 g are described below according to the specific parameters of the fastening system 120 described in the `` Method of Manufacturing '' above. It is made like The complementary receiving surface 153 used in connection with the fastening system 120 is the Milliken 970026 stitch bonded loop fabric described above.

Fastening system 120 has a width of at least about 2.54c
m (1 inch) and may be of any length to provide a convenient user end 158, at least about 3.5 c
A length of m (1.4 inches) is preferred. The array of prongs of the fastening system 120 constitutes a matrix with about 26 prongs per cm 2 (169 prongs per square inch). These prongs are preferably oriented in substantially the same direction and face the end 158 of the fastening tape user.

In use, the first torso portion 142 is positioned around the wearer's back and the remainder of the diaper 110 is positioned such that the second torso portion 144 is positioned over the wearer's front. The diaper 110 is applied to the wearer by pulling in between, and then the user's end 158 of the fastening system 120 is secured to the outer surface of the second torso portion 144, forming a side closure.

────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Cox, Robert George Jr., Cincinnati, Susannah, Drive, Ohio, USA, 3780 (56) References JP-A-3-198802 (JP, A) Japanese Utility Model 2 −88626 (JP, U) JP 51-2512 (JP, B1) (58) Fields investigated (Int. Cl. ⁷ , DB name) A44B 18/00

Claims (10)

(57) [Claims] 1. A step of heating a heat-sensitive material to at least a melting point, a step of providing a substrate to be transferred in a first direction, and depositing individually separated amounts of the heat-sensitive material on a substrate to be transferred. And elongating the individually separated amounts of the thermosensitive material in a direction having a vector component parallel to the plane of the substrate; and cutting the elongated thermosensitive material to include a distal end and an engaging means. Forming a prong with a shank comprising the steps of:
A method for producing a fastening material, comprising the step of providing an azimuth of 0 °, preferably 45 ° to 135 °, more preferably 60 ° to 120 °. 2. The method of claim 1, wherein the step of azimuthally shank includes the step of pressing the prong with the newly formed but not yet solidified prongs. How to make. 3. The method according to claim 2, wherein the step of pressing the prongs includes the step of applying a fluid pressure difference to at least a portion of the prongs in a direction having a vector component perpendicular to the first direction. For producing a fastening material of the invention. 4. The method of claim 1, wherein the step of applying a fluid pressure differential comprises flowing a gas, preferably a substantially stratified gas stream, more preferably, said gas flow having a pressure difference of 1 pound to 10 pounds per square inch from a high pressure region to a low pressure. 4. The method of manufacturing a fastening material according to claim 3, comprising the step of flowing across the substrate to an area. 5. The method of claim 1, wherein flowing the laminar gas stream across the substrate comprises flowing the gas through at least one flow amplifier, wherein the flowing the gas preferably comprises a first flow amplifier and a second flow amplifier. 5. The method of claim 4, wherein a flow amplifier is used and the output of the first flow amplifier is drawn into the suction of the second flow amplifier. 6. The method of claim 2, wherein the step of pressing the prongs includes the step of applying gravity to the prongs. 7. The method of applying gravity to the prongs comprises tilting the substrate vertically relative to horizontal, preferably tilting the substrate at least about 15 °, and more preferably tilting the substrate at least about 30 °. A method for producing a fastening material according to claim 6, characterized in that: 8. The method of claim 2, wherein the step of pressing the prongs includes both applying a fluid pressure difference to the prongs and applying gravity to the prongs. . 9. A fastening material for attaching to a complementary receiving surface, the fastening material comprising: a substrate; at least one prong having a shank joined at a base to the substrate; and a shank joined to the shank. Engagement means projecting laterally beyond the periphery of the shank, the shank having a proximal end adjacent the base and projecting outwardly from the substrate, the shank having a leading edge angle and a trailing edge. An angle, wherein the leading edge angle is substantially different from the trailing edge angle, the shank is oriented in a direction other than perpendicular to the plane of the substrate, and the shank is between 20 ° and 16 °.
A fastening material having an azimuth of 0 °, preferably 45 ° to 135 °, more preferably 60 ° to 120 °. 10. A topsheet, a backsheet joined to the topsheet, an absorbent core disposed between the topsheet and the backsheet, and a fastening manufactured by the method of claim 1. A fastening system comprising a material or a fastening material according to claim 9.